JAY SHRIRAM GROUP OF INSTITUTIONS

AVINASHIPALAYAM, TIRUPUR.

AUTOMATIC GEAR CHANGER IN TWO WHEELERS - DC

GUN MODEL

PROJECT REPORT - 2012 – 2013

Submitted by

D.VADIVEL. ITI,DME.BE,MISTE.,
In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
IN

MECHANICAL ENGINEERING

ANNA UNIVERSITY
CHENNAI.MAY–2013
 BONAFIDE CERTIFICATE

Certified that this project report “AUTOMATIC GEAR CHANGER IN

TWO WHEELERS - DC GUN MODEL” is the bonafide work of
D.VADIVEL

Who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Prof.V.Suresh Dr.R.MAGUTEESHWARAN
SUPERVISOR. HEAD OF THE DEPARTMENT.
Mechanical engineering Mechanical engineering
Jay Shriram group of institution, Jay Shriram group of institution,
Tirupur Tirupur.

Submitted for the University Project Viva-voice held on -MAY 2013

 ACKNOWLEDGEMENT

We express our deepest gratitude to our Chairman

Mr.K.M.Thangaraj, for his invaluable guidance and blessing.
We would like to thank our vice chairman
Mr.Karuppannaswamy for his unwavering support during the entire course
of this project.
We are grateful to our honorable Treasurer Mr. T.Govindasamy for
his kind cooperation and providing us lab facilities to work for our project.
We are very grateful to our Principal Dr.C.Rameshkumar for
providing us with an environment to complete our project successfully.
We are deeply indebted to our Vice Principal/Head of the
Department Dr.R.Maguteeswaran, who modeled us both technically and
morally for achieving greater success in life.
We express our sincere thanks to Mr.P.Satheesh for his constant
encouragement and support throughout our course, especially for the useful
suggesting given during the course of the project period.
We are very grateful to our project co-coordinator Prof.V.Suresh
for being instrumental in the completion of our project with his complete
guidance.
We also thank all the staff members of our college and technicians
for their help in making this project a successful one.
Finally, we take this opportunity to extend our deep appreciation to
our family and friends, for all that they meant to us during the crucial times of
the completion of our project.
AUTOMATIC GEAR CHANGER IN TWO
WHEELERS - DC GUN MODEL
CONTENTS
 CONTENTS

CHAPTER TITLE
NO
SYNOPSIS

LIST OF FIGURES

1 Introduction

2 Literature review

3 Description of equipments

3.1 Spring

3.2 DC Gun

3.3 Tape motor

3.4 U-slot sensor

3.5 Relay

3.6 Control unit

4 Design and drawing

4.1 Machine Components

4.2 Block diagram

4.3 Overall diagram

5 Working principle

6 Merits & demerits

7 Applications

8 List of materials

9 Cost Estimation

10 Conclusion
Bibliography

photography
LIST OF FIGURES
 LIST OF FIGURES

Figure TITLE
Number

1 Block diagram

2 Overall diagram
SYNOPSIS
 SYNOPSIS

The main objective of this concept is used to apply the gear by using

automation system in automobiles. This is the new innovative model mainly used for

the vehicles to control the vehicle. In this project we design the automatic gear

changing mechanism in two wheeler vehicles by using the electronic devices. This is

very useful for the gear changing mechanism in automobile vehicles. By using this

we can easily control the vehicle and improve the performance of the vehicle also we

can avoid the wear and tear of the gear.

 CHAPTER-1

INDRODUCTION
 CHAPTER-1

INDRODUCTION
A motorcycle (also called a motor bicycle, motorbike, bike, or cycle) is a

single-track, two-wheeled motor vehicle powered by an engine. Motorcycles vary

considerably depending on the task for which they are designed, such as long

distance travel, navigating congested urban traffic, cruising, sport and racing, or off-

road conditions. In many parts of the world, motorcycles are among the least

expensive and most widespread forms of motorized transport.

In the two wheelers the transmission is carried out by manually.

This may result in fatigue during driving in cities or traffic areas.

 CHAPTER-2

LITERATURE SURVEY
 CHAPTER-II

LITERATURE SURVEY

MOTOR CYCLE:
The first motorcycle was designed and built by the German inventors Gottlieb

Daimler and Wilhelm Maybach in Bad Cannstatt in 1885. The first petroleum-

powered vehicle, it was essentially a motorised bicycle, although the inventors called

their invention the Reitwagen ("riding car"). However, if a two-wheeled vehicle with

steam propulsion is considered a motorcycle, then the first one may have been

American. One such machine was demonstrated at fairs and circuses in the eastern

U.S. in 1867, built by Sylvester Howard Roper of Roxbury, Massachusetts.

In 1894, Hildebrand & Wolf Muller became the first motorcycle available for

purchase. In the early period of motorcycle history, many producers of bicycles

adapted their designs to accommodate the new internal combustion engine. As the

engines became more powerful and designs outgrew the bicycle origins, the number

of motorcycle producers increased

Until the First World War, the largest motorcycle manufacturer in the world

was India, producing over 20,000 bikes per year. By 1920, this honor went to Harley-

Davidson, with their motorcycles being sold by dealers in 67 countries. In 1928,

DKW took over as the largest manufacturer.

 After the Second World War, the BSA Group became the largest producer of

motorcycles in the world, producing up to 75,000 bikes per year in the 1950s. The

German company NSU Motorenwerke AG held the position of largest manufacturer

from 1955 until the 1970s.

NSU Sportmax streamlined motorcycle, 250 cc class winners of the 1955

Grand Prix seasonIn the 1950s, streamlining began to play an increasing part in the

development of racing motorcycles and held out the possibility of radical changes to

motorcycle design. NSU and Moto-Guzzi were in the vanguard of this development

both producing very radical designs well ahead of their time. NSU produced the most

advanced design, but because of the deaths of four NSU riders in the 1954–1956

seasons, they abandoned further development and quit Grand Prix motorcycle

racing. Moto-Guzzi produced competitive race machines, and by 1957 nearly all the

Grand Prix races were being won by streamlined machines.

From the 1960s through the 1990s, small two-stroke motorcycles were

popular worldwide, partly as a result of East German Walter Kaaden's engine work in

the 1950s.

Today, the Japanese manufacturers, Honda, Kawasaki, Suzuki, and Yamaha

dominate the motorcycle industry, although Harley-Davidson still maintains a high

degree of popularity in the United States. Apart from these high capacity

motorcycles, there is a very huge market for low capacity (less then 300 cc)

motorcycles, mostly concentrated in Asian and African countries. This area is

dominated by mostly Indian companies with Hero Honda being the world's largest
manufacturer of two wheelers. Its Hero Honda Splendor model is the highest selling

motorcycle in automotive history, having sold more then 8.5 million to date.

A 2006 Honda HeroRecent years have also seen resurgence in the popularity

of several other brands sold in the U.S. market, including BMW, KTM, Triumph,

Aprilia, Moto-Guzzi, MV Agusta and Ducati.

Outside of the U.S., these brands have enjoyed continued and sustained

success, although Triumph, for example, has been re-incarnated from its former self

into a modern world-class manufacturer. In overall numbers, however, the Chinese

currently manufacture and sell more motorcycles than any other country and exports

are rising.

Additionally, the small-capacity scooter is very popular through most of the

world. The Piaggio group of Italy, for example, is one of the world's largest producers

of two-wheeled vehicles.

All these motorcycles are conventional ones that means they use

conventional energy source such as fossil fuels (petrol, diesel) which produce

harmful gases such as CO2, carbon monoxide, NO, etc. which cause air pollution as

well as Global warming.

Keeping these facts in mind and also the possible extinction of fossil fuels in another

100 years we have to reduce the use of such fuels and look for other energy sources

and here we have powered the two wheeler using electricity produced while it’s

running on the petrol/ diesel.

The principle of conversion of electrical energy into mechanical energy by

electromagnetic means was demonstrated by the British scientist Michael Faraday in

1821 and consisted of a free-hanging wire dipping into a pool of mercury. A

permanent magnet was placed in the middle of the pool of mercury. When a current

was passed through the wire, the wire rotated around the magnet, showing that the

current gave rise to a circular magnetic field around the wire. This motor is often

demonstrated in school physics classes, but brine (salt water) is sometimes used in

place of the toxic mercury. This is the simplest form of a class of electric motors

called homopolar motors. A later refinement is the Barlow's Wheel. These were

demonstration devices, unsuited to practical applications due to limited power.

The first real electric motor, using electromagnets for both stationary and

rotating parts, was demonstrated by Ányos Jedlik in 1828 Hungary. He built an

electric-motor propelled vehicle in 1828.

The first English commutator-type direct-current electric motor capable of a

practical application was invented by the British scientist William Sturgeon in 1832.

Following Sturgeon's work, a commutator-type direct-current electric motor made

with the intention of commercial use was built by the American Thomas Davenport

and patented in 1837. Although several of these motors were built and used to

operate equipment such as a printing press, due to the high cost of primary battery

power, the motors were commercially unsuccessful and Davenport went bankrupt.

Several inventors followed Sturgeon in the development of DC motors but all

encountered the same cost issues with primary battery power. No electricity

distribution had been developed at the time. Like Sturgeon's motor, there was no

practical commercial market for these motors.

 The modern DC motor was invented by accident in 1873, when Zénobe

Gramme connected the dynamo he had invented to a second similar unit, driving it

as a motor. The Gramme machine was the first electric motor that was successful in

the industry.

In 1888 Nikola Tesla invented the first practicable AC motor and with it the

polyphase power transmission system. Tesla continued his work on the AC motor in

the years to follow at the Westinghouse Company.

 CHAPTER-3

DESCRIPTION OF EQUIPMENT
 CHAPTER-III

DESCRIPTION OF EQUPMENTS

3.1. SPRING

The automobile chassis is mounted on the axles not direct but through some

form of springs. This is done to isolate the vehicle body from the road shocks which

may be in the form of bounce, pitch, roll or sway. These tendencies give rise to an

uncomfortable ride and also cause additional stress in the automobile frame and

body. All the parts which perform the function of isolating the automobile from the

road shocks are collectively.

A Springing device must be a compromise between flexibility and stiffness. If

it is more rigid, it will not absorb road shocks efficiently and if it is more flexible it will

continue to vibrate even after the bump has passed so we must have sufficient

damping of the spring to prevent excessive flexing.

RETURN SPRING

A spring is a flexible elastic object used to store mechanical

energy. Springs are usually made out of hardened steel. Small springs

can be wound from pre-hardened stock, while larger ones. A spring is a

mechanical device, which is typically used to store energy and

subsequently release it, to absorb shock, or to maintain a force between

contacting surfaces. They are made of an elastic material formed into

the shape of a helix which returns to its natural length when unloaded

this is called return spring. Springs are placed between the road wheels

and the vehicle body. When the wheel comes across a bump on the

road, it rises and deflects the spring, thereby storing energy therein. On

releasing, due to the elasticity of the spring, material, it rebounds thereby

expending the stored energy. In this way the spring starts vibrating, with

amplitude decreasing gradually on internal friction of the spring material

and friction of the suspension joints till vibrations die down.

3.2 D.C GUN:
INTRODUCTION:

In 1918, French inventor Louis Octave Fauchon-Villeplee invented

electric cannon which bear a strong resemblance to the linear motor. He

filed for a US patent on 1 April 1919, which was issued in July 1922 as

patent no. 1,421,435 "Electric Apparatus for Propelling Projectiles". In

his device, two parallel busbars are connected by the wings of a

projectile, and the whole apparatus surrounded by a magnetic field. By

passing current through busbars and projectile, a force is induced which

propels the projectile along the bus-bars and into flight.

During World War II the idea was revived by Joachim Hänsler of

Germany's Ordnance Office, and an electric anti-aircraft gun was

proposed. By late 1944 enough theory had been worked out to allow the

Luftwaffe's Flak Command to issue a specification, which demanded a

muzzle velocity of 2,000 m/s (6,600 ft/s) and a projectile containing

0.5 kg (1.1 lb) of explosive. The guns were to be mounted in batteries of

six firing twelve rounds per minute, and it was to fit existing 12.8 cm FlaK

40 mounts. It was never built. When details were discovered after the

war it aroused much interest and a more detailed study was carried out,

culminating in a 1947 report which concluded that it was theoretically

feasible, but that each gun would need enough power to illuminate half

of Chicago

CONSTRUCTION:

A railgun consists of two parallel metal rails (hence the name)

connected to an electrical power supply. When a conductive projectile is

inserted between the rails (from the end connected to the power supply),

it completes the circuit. Electrons flow from the negative terminal of the

power supply up the negative rail, across the projectile, and down the

positive rail, back to the power supply.

This current makes the railgun behave similar to an electromagnet,

creating a powerful magnetic field in the region of the rails up to the

position of the projectile. In accordance with the right-hand rule, the

magnetic field circulates around each conductor. Since the current is in

opposite direction along each rail, the net magnetic field between the

rails (B) is directed vertically. In combination with the current (I) across

the projectile, this produces a Lorentz force which accelerates the

projectile along the rails. There are also forces acting on the rails

attempting to push them apart, but since the rails are firmly mounted,
they cannot move. The projectile slides up the rails away from the end

with the power supply.

A very large power supply providing, on the order of, one million

amperes of current will create a tremendous force on the projectile,

accelerating it to a speed of many kilometres per second (km/s). 20 km/s

has been achieved with small projectiles explosively injected into the

railgun. Although these speeds are theoretically possible, the heat

generated from the propulsion of the object is enough to rapidly erode

the rails. Such a railgun would require frequent replacement of the rails,

or use a heat resistant material that would be conductive enough to

produce the same effect.

CONSIDERATIONS IN RAILGUN DESIGN

MATERIALS

The rails and projectiles must be built from strong conductive

materials; the rails need to survive the violence of an accelerating

projectile, and heating due to the large currents and friction involved.

The recoil force exerted on the rails is equal and opposite to the force

propelling the projectile. The seat of the recoil force is still debated. The

traditional equations predict that the recoil force acts on the breech of

the railgun. Another school of thought invokes Ampère's force law and

asserts that it acts along the length of the rails (which is their strongest

axis). The rails also repel themselves via a sideways force caused by

the rails being pushed by the magnetic field, just as the projectile is. The

rails need to survive this without bending, and must be very securely

mounted.

DESIGN CONSIDERATIONS

The power supply must be able to deliver large currents, sustained

and controlled over a useful amount of time. The most important gauge

of power supply effectiveness is the energy it can deliver. As of February

2008, the largest known energy used to propel a projectile from a railgun
was 32 million joules.. The most common forms of power supplies used

in railguns are capacitors and compulsators.

The rails need to withstand enormous repulsive forces during firing, and

these forces will tend to push them apart and away from the projectile.

As rail/projectile clearances increase, arcing develops, which causes

rapid vaporization and extensive damage to the rail surfaces and the

insulator surfaces. This limited some early research railguns to one shot

per service interval.

The inductance and resistance of the rails and power supply limit

the efficiency of a railgun design. Currently different rail shapes and

railgun configurations are being tested, most notably by the United

States Navy, The Institute for Advanced Technology, and BAE Systems.

HEAT DISSIPATION

Massive amounts of heat are created by the electricity flowing

through the rails, as well as the friction of the projectile leaving the

device. The heat created by this friction itself can cause thermal

expansion of the rails and projectile, further increasing the frictional heat.

This leads to three main problems: melting of equipment, safety of

personnel, and detection by enemy forces. As briefly discussed above,

the stresses involved in firing this sort of device require an extremely

heat-resistant material. Otherwise the rails, barrel, and all equipment

attached would melt or be irreparably damaged.

In practice the rails are, with most designs of railgun, subject to

erosion due to each launch; and projectiles can be subject to some

degree of ablation also, and this can limit railgun life, in some cases

severely.

MATHEMATICAL FORMULA

In relation to railgun physics, the magnitude of the force vector can

be determined from a form of the Biot-Savart Law and a result of the

Lorentz force. It can be expressed mathematically in terms of the

permeability constant (μ0), the radius of the rails (which are assumed to

be circular in cross section)(r), the distance between the counterpoints of

the rails(d) and the current in amps through the system (I) as follows

The formula is based on the assumption that the distance(l)

between the point where the force (F) is measured and the beginning of

the rails is greater than the separation of the rails (d) by a factor of about

3 or 4 (l > 3d). Some other simplifying assumptions have also been

made; to describe the force more accurately, the geometry of the rails

and the projectile must be taken into consideration.

RAIL GUN:

Railguns are being pursued as weapons with projectiles that do

not contain explosives, but are given extremely high velocities: 3500 m/s

(11,500 ft/s, approximately Mach 10 at sea level) or more (for

comparison, the M16 rifle has a muzzle speed of 930 m/s, or 3,000 ft/s),

which would make their kinetic energy equal or superior to the energy

yield of an explosive-filled shell of greater mass. This would allow more

ammunition to be carried and eliminate the hazards of carrying

explosives in a tank or naval weapons platform. Also, by firing at higher

velocities railguns have greater range, less bullet drop and less wind

drift, bypassing the inherent cost and physical limitations of conventional

firearms - "the limits of gas expansion prohibit launching an unassisted

projectile to velocities greater than about 1.5 km/s and ranges of more

than 50 miles [80 km] from a practical conventional gun system."

If it were possible to apply the technology as a rapid-fire automatic

weapon, a railgun would have further advantages in increased rate of

fire. The feed mechanisms of a conventional firearm must move to

accommodate the propellant charge as well as the ammunition round,

while a railgun would only need to accommodate the projectile.

Furthermore, a railgun would not have to extract a spent cartridge case

from the breech, meaning that a fresh round could be cycled almost

immediately after the previous round has been shot.

RESISTANCE

Electrical resistance is a major limitation because when dumping

large amounts of electrical energy into a conductor the majority of the

energy is converted to heat due to resistance and therefore effectively

lost as it is not driving the projectile. This could be overcome through the

use of a superconducting material.

ENERGY DISSIPATION

The coils have an electrical resistance, and resistive losses are

often very significant indeed.

The energy in the magnetic field itself does not simply dissipate;

much of it returns to the capacitor when the electric current is

decreasing. Unfortunately it does this in the reverse direction (via a

'ringing' mechanism due to inductance of the coils), which can seriously

damage polarized capacitors (such as electrolytics).

In the circuit the magnetic field keeps the current in the coil flowing

after the capacitor has discharged, so that it keeps discharging and

builds up a negative voltage (see Lenz's law). This is similar to an LC

oscillator.

The capacitor charging to a negative voltage can be prevented by

placing a diode across the capacitor terminals.

Some designs bypass this limitation by using couple of diodes.

Then, diodes reverse polarity to charge capacitors instead with proper

polarity again, effectively re-using remaining coil energy.

A coilgun is a type of synchronous linear electric motor which is

used as a projectile accelerator that consists of one or more

electromagnetic coils. These are used to accelerate a magnetic

projectile to high velocity. The name Gauss gun is sometimes used for

such devices in reference to Carl Friedrich Gauss, who formulated

mathematical descriptions of the electromagnetic effect used by

magnetic accelerators.

Coilguns consist of one or more coils arranged along the barrel

that are switched in sequence so as to ensure that the projectile is

accelerated quickly along the barrel via magnetic forces. Coilguns are

distinct from railguns, which pass a large current through the projectile or
sabot via sliding contacts. Coilguns and railguns also operate on

different principles.

ELCTRO MAGNATIC GUN DETAILS:

While playing with my can crusher, I noticed that a can placed off center

tended to be pushed out of the solenoid. A little searching of the patent literature

convinced me that I had inadvertently created a very poor, single stage, coil

gun. Presented below is a summary of what I have found so far.

Propellant powered guns are typically limited to muzzle velocities on the order

of 2,000 meters per second. This limit is inherent to the use of expanding gas to

drive the projectile down a barrel. Barrels simply can't withstand the temperatures

and pressures required for higher expansion rates of the propellant combustion

products (normally CO2 and NOx). One attempt at a gun for higher velocities used

differential pistons (a large one, driven by methane/oxygen combustion, connected

to a small one for compression of the drive gas) to provide a high pressure of

hydrogen gas (hydrogen is the lightest, and hence fastest expanding, of all

gasses). While some success was achieved, the apparatus was cumbersome and

the velocities were still limited. For some applications, particularly orbital launching,

this is insufficient (earth escape velocity is 11,200 m/s).

Two basic types of electromagnetic gun are described in the patent literature,

the rail gun and the coil gun. Both use stored energy sources to produce a large

magnetic field and a high electric current through a driving armature. The interaction

of the current with the magnetic field generates a force which propels the armature
(and any projectile connected to it). Beyond that, they differ substantially, and each

has practical difficulties which has prevented them from being more than laboratory

curiosities.

3.3 TAPE MOTOR

An audio tape recorder, tape deck, reel-to-reel tape deck, cassette deck or

tape machine is an audio storage device that records and plays back sounds,

including articulated voices, usually using magnetic tape, either wound on a reel or in

a cassette, for storage. It its present day form, it records a fluctuating signal by

moving the tape across a tape head that polarizes the magnetic domains in the tape

in proportion to the audio signal.

ELECTRICAL

Electric current flowing in the coils of the tape head creates a fluctuating

magnetic field. This causes the magnetic material on the tape, which is moving past

and in contact with the head, to align in a manner proportional to the original signal.

The signal can be reproduced by running the tape back across the tape head, where

the reverse process occurs – the magnetic imprint on the tape induces a small

current in the read head which approximates the original signal and is then amplified

for playback. Many tape recorders are capable of recording and playing back at once

by means of separate record and playback heads in line or combined in one unit.

MECHANICAL

Modern professional recorders usually use a three-motor scheme. One motor

with a constant rotation speed drives the capstan. This, usually combined with a
rubber pinch roller, ensures that the tape speed does not fluctuate. Of the other two

motors, one applies a very light torque to the supply reel, and the other a greater

torque to the take-up reel, to maintain the tape's tension. During fast winding

operation the pinch roller is disengaged and the reel motors provide the necessary

power. The cheapest models use a single motor for all required functions; the motor

drives the capstan directly and the supply and take-up reels are loosely coupled to

the capstan motor with slipping belts or clutches. There are also variants with two

motors, in which one motor is used for rewinding only.

Specifications

1. High quality, low price.

2. Long life, low noise.

3. OEM, new design.

4. Smooth and quiet operation.

Typical applications:

1) Cassette Tape recorder

2) Audio

3) Other industrial equipment Packing:

200pcs/carton

Volume: 0.029cbm

N.W.: 15.5kg

G.W.: 16.0kg
Specifications:

Technical Characteristic(only for reference, we are capable of meeting the sourcing

needs of diverse buyer).

3.4 U-SLOT SENSOR:

The slot sensors are U-shaped and the active face is located between the two

arms. The sensor is actuated when an object passes the slot. Slot sensors detect

laterally approaching targets reliably, regardless of their distance to the active face.

Slot sensors, sometimes called optical fork sensors because of their "forked"

shape, detect objects that pass between the two arms—one with the emitter, the

other with the receiver. The fixed slot width provides reliable opposed-mode sensing

of objects as small as 0.30 mm.

The ultra-small PM series of u-shaped photoelectric sensors provides a wide

range of 29 different models to suit any of your application needs. With the industry's

smallest size, the PM series plays a key role in the miniaturization of your

equipment. All models are equipped with two outputs, one for Light-ON and the other

for Dark-ON sensing. This increases the versatility of the sensor for use in existing

applications. The series is also available in a connector type to maximize ease of

installation and allow for wire replacement if the cable is severed. The PM series

conforms to the European EMC Directive and carries UL Recognition.

BGL Series
 The BGL series of photoelectric slot sensors offer laser-like accuracy with

highly visible red LED or Class II laser emission for resolutions down to 0.3mm.

These self-contained thru beam sensors, configured in a simple “U” shaped housing,

save mounting and machine setup time. Typical thru-beam fiber optic applications

can be solved using BGL slot sensors, saving installation time and cost. Since the

BGL slot sensor is completely self-contained, it replaces the two thru-beam cables

and the fiber optic amplifier, eliminating the need for special mounting brackets.

FEATURES

– Highly visible emission

– Extremely rugged single piece metal housing

– High resolution

– Light/Dark operation selectable

– High switching frequency

– Adjustable sensitivity

– M8 connection with 3600 LED indicator

APPLICATIONS

– Parts sensing on conveyer rails and conveying belts

– Label discrimination with transparent substrates

– Parts dimension verification

– Parts counting in assembly lines

– Tool break monitoring

– Position verification
– Feed verification on automatic assembly equipment

– Checking for complete count

– Level monitoring in tanks

– Handling and assembly technology

With opposed mode sensing pairs in U-shaped housings Banner

SL10 & SL30 Series Slot Sensors are ideal for sensing of color marks on

clear film.

 Holds easy-to-use opposed mode sensor pairs in rugged U-shaped housing

 Available with 10 mm sensing slot (SL10 models) or 30 mm sensing slot

(SL30 models)

 Ideal for detecting registration marks, holes or gear teeth; edge guiding; and

counting

 Features molded-in beam guides to simplify installation and alignment

 Offers fixed sensitivity, 4-turn manual sensitivity adjustment or push-button

programming, depending on model

 Uses either visible red or infrared sensing beam, depending on model

If you are looking for Banner Slot Sensors, please call us on (800) 894 - 0412 or

email us at info@clrwtr.com we will do our best to help you find the Banner SLM

Series Sensor that you are looking for at the most competitive prices possible. If you

are searching for Banner C-GAGE Label Sensors technical information (data-sheets)

please use the Banner Datasheets OR Product Selection Guide page links.
 The SR31 series is composed of slot sensors with infrared LED

emission, distinguished by an elevated 10 kHz switching frequency and

by a sturdy and compact metal housing. The detection sensitivity is

adjusted by means of a trimmer. The dark/light operating mode is

configured according to the connection. The series includes M8

connector versions with NPN output, or PNP output; cable versions

present both NPN/PNP outputs. The SR31 sensors have a 30 mm wide

and 42 mm deep slot. These sensors are suitable for detecting opaque

labels on a transparent support, to control material presence and

continuity, to detect synchronism pulses on toothed or holed wheels, or

as on-off edge guide.

 Infrared LED emission

 Sensitivity trimmer adjustment

 Elevated switching frequency

 Metal housing with wide slot

3.5 RELAY

A relay is an electrically operated switch. Current flowing through

the coil of the relay creates a magnetic field which attracts a lever and

changes the switch contacts. The coil current can be on or off. So relays

have two switch positions and they are double throw (changeover)
switches. Relays allow one circuit to switch a second circuit which can

be completely separate from the first. The link is magnetic and

mechanical. The coil of a relay passes a relatively large current,

typically 30mA for a 12V relay, but it can be as much as 100mA for

relays designed to operate from lower voltages. Most ICs (chips) cannot

provide this current and a transistor is usually used to amplify the small

IC current to the larger value required for the relay coil. The maximum

output current for the popular 555 timer IC is 200mA so these devices

can supply relay coils directly without amplification.

Relays are usually SPDT or DPDT but they can have many

more sets of switch contacts, for example relays with 4 sets of

changeover contacts are readily available. Most relays are designed for

PCB mounting but you can solder wires directly to the pins providing you

take care to avoid melting the plastic case of the relay. The animated

picture shows a working relay with its coil and switch contacts. You can

see a lever on the left being attracted by magnetism when the coil is

switched on. This lever moves the switch contacts. There is one set of

contacts (SPDT) in the foreground and another behind them, making the

relay DPDT.
3.6 CONTROL UNIT:

MICROCONTROLLER:

INTRODUCTION:

Microcontrollers are destined to play an increasingly important role in

revolutionizing various industries and influencing our day to day life more strongly

than one can imagine. Since its emergence in the early 1980's the microcontroller

has been recognized as a general purpose building block for intelligent digital

systems. It is finding using diverse area, starting from simple children's toys to highly

complex spacecraft. Because of its versatility and many advantages, the application

domain has spread in all conceivable directions, making it ubiquitous. As a

consequence, it has generate a great deal of interest and enthusiasm among

students, teachers and practicing engineers, creating an acute education need for

imparting the knowledge of microcontroller based system design and development. It

identifies the vital features responsible for their tremendous impact, the acute

educational need created by them and provides a glimpse of the major application

area.

MICROCONTROLLER:

A microcontroller is a complete microprocessor system built on a single IC.

Microcontrollers were developed to meet a need for microprocessors to be put into

low cost products. Building a complete microprocessor system on a single chip

substantially reduces the cost of building simple products, which use the

microprocessor's power to implement their function, because the microprocessor is a

natural way to implement many products. This means the idea of using a
microprocessor for low cost products comes up often. But the typical 8-bit

microprocessor based system, such as one using a Z80 and 8085 is expensive. Both

8085 and Z80 system need some additional circuits to make a microprocessor

system. Each part carries costs of money. Even though a product design may

requires only very simple system, the parts needed to make this system as a low

cost product.

To solve this problem microprocessor system is implemented with a single

chip microcontroller. This could be called microcomputer, as all the major parts are in

the IC. Most frequently they are called microcontroller because they are used they

are used to perform control functions.

The microcontroller contains full implementation of a standard

MICROPROCESSOR, ROM, RAM, I/0, CLOCK, TIMERS, and also SERIAL PORTS.

Microcontroller also called "system on a chip" or "single chip microprocessor system"

or "computer on a chip".

A microcontroller is a Computer-On-A-Chip, or, if you prefer, a single-chip

computer. Micro suggests that the device is small, and controller tells you that the

device' might be used to control objects, processes, or events. Another term to

describe a microcontroller is embedded controller, because the microcontroller and

its support circuits are often built into, or embedded in, the devices they control.

Today microcontrollers are very commonly used in wide variety of intelligent

products. For example most personal computers keyboards and implemented with a

microcontroller. It replaces Scanning, Debounce, Matrix Decoding, and Serial

transmission circuits. Many low cost products, such as Toys, Electric Drills,
Microwave Ovens, VCR and a host of other consumer and industrial products are

based on microcontrollers.

Microcontroller is a general purpose device, which integrates a number of

the components of a microprocessor system on to single chip. It has inbuilt CPU,

memory and peripherals to make it as a mini computer. A microcontroller combines

on to the same microchip:

 The CPU core

 Memory(both ROM and RAM)

 Some parallel digital i/o

Microcontrollers will combine other devices such as:

 A timer module to allow the microcontroller to perform tasks for certain

time periods.

 A serial i/o port to allow data to flow between the controller and other

devices such as a PIC or another microcontroller.

 An ADC to allow the microcontroller to accept analogue input data for

processing.

Microcontrollers are:

 Smaller in size

 Consumes less power

 Inexpensive
 Micro controller is a stand alone unit, which can perform functions on its own

without any requirement for additional hardware like i/o ports and external memory.

The heart of the microcontroller is the CPU core. In the past, this has traditionally

been based on a 8-bit microprocessor unit. For example Motorola uses a basic 6800

microprocessor core in their 6805/6808 microcontroller devices.

In the recent years, microcontrollers have been developed around specifically

designed CPU cores, for example the microchip PIC range of microcontrollers.

CHAPTER-4
DESIGN AND DRAWING
 CHAPTER-4

DESIGN AND DRAWING

4.1 MACHINE COMPONENTS

The automatic gear changer in two wheelers- DC gun model is consists of the

following components to full fill the requirements of complete operation of the

machine.

 Tape motor

 U-Slot sensor

 Control unit

 DC gun

 Spring to Gear Box

DRAWING
4.2 BLOCK DIAGRAM
4.3 DRAWING FOR AUTOMATIC GEAR CHANGER IN TWO

WHEELERS - DC GUN MODEL

 CHAPTER -5

WORKING PRINCIPLE
 CHAPTER-V

WORKING PRINCIPLE
Here we have two dc gun arrangements which are arranged on either side of

the vehicle pedal rest for applying the gear. The dc gun is fixed at the end of the flat

pedal rest. The plate rest has pivot at the center. The guns are operated with the

help of electric power supply and it is controlled by the control unit. One of the guns

is used to apply the gear and another one for reducing the gears. The gears are

applied on the vehicle depending up on the speed of the vehicle. The speed sensors

are placed near the wheel the sensor sense the signal and give the output signal to

the control unit. For this purpose, here we are using a tape motor with a U slot

sensor such that the speed can be varied through the tape motor. Depending up on

the signal the clutch and gears will automatically changed with the help of the control

unit. When the vehicle speed increases automatically the clutch and the gear will

change in the vehicles. The arrangement is clearly shown in the below diagram.
 CHAPTER -6

MERITS AND DEMERITS

 CHAPTER-VI

MERITS AND DEMERITS

MERITS

 Automatic method

 Quick response is achieved

 Simple in construction

 Easy to maintain and repair

 Cost of the unit is less

 Continuous operation is possible without stopping

DEMERITS

We need to alter gear shifter which may increase the vehicles weight and will

reduce the drivers comfort.

 CHAPTER -7

APPLICATIONS
 CHAPTER-VII

APPLICATIONS

It is applicable in all types of two wheelers which has gear transmission.

 CHAPTER-8

LIST OF MATERIALS
 CHAPTER-VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.

1. Properties:

The material selected must posses the necessary properties for the proposed

application. The various requirements to be satisfied. Can be weight, surface finish,

rigidity, ability to withstand environmental attack from chemicals, service life,

reliability etc.

The following four types of principle properties of materials decisively affect

their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,

electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance, impact
resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness, wear

resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may demand

the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material.

For example, it would never be desirable to go casting of a less number of

components which can be fabricated much more economically by welding or hand

forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply. It then becomes obligatory

for the designer to use some other material which though may not be a perfect

substitute for the material designed. the delivery of materials and the delivery date of

product should also be kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an

important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance

of the designed part are involved in the selection of proper materials.

 CHAPTER-9

COST ESTIMATION
 CHAPTER-IX

COST ESTIMATION
1. LABOUR COST:

Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost

2. OVERGHEAD CHARGES:

The overhead charges are arrived by ”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

=6000+1200

=7200

Overhead Charges =20%of the manufacturing cost

=2000

3. TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =6000+1200+2000=9200

CHAPTER-10

CONCLUSION
 CHAPTER-X

CONCLUSION

The project carried out by us made an impressing task in the field of

automobile department. It is very useful for driver while drive the vehicle at any

places without any tension.

This project has also reduced the cost involved in the concern. Project has

been designed to perform the entire requirement task which has also been provided.
BIBLIOGRAPHY
 BIBLIORAPHY

1. Design data book -P.S.G.Tech.

2. Machine tool design handbook – Central machine tool

Institute, Bangalore.

3. Strength of Materials - R.S.Kurmi

4. Manufacturing Technology - M.Haslehurst.

5. Design of machine elements- R.s.Kurumi